Multi-component rotor for an electric motor of an appliance

ABSTRACT

A motor for a laundry appliance includes a drive shaft coupled to a drum at a first end. The rotor frame is coupled proximate the second end of the drive shaft, where the rotor frame includes at least one polymeric material. A central hub includes a core and a perimetrical ring that extends circumferentially around the core. A plurality of recesses are defined within a planar surface of the perimetrical ring, wherein a portion of the polymeric material is received within the plurality of recesses to secure the rotor frame to the central hub.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 17/101,371 filed Nov. 23, 2020, entitled MULTI-COMPONENT ROTORFOR AN ELECTRIC MOTOR OF AN APPLIANCE, which is a continuation of U.S.patent application Ser. No. 16/395,600 filed Apr. 26, 2019, entitledMULTI-COMPONENT ROTOR FOR AN ELECTRIC MOTOR OF AN APPLIANCE, now U.S.Pat. No. 10,897,167, which is a continuation of U.S. patent applicationSer. No. 14/965,953 filed Dec. 11, 2015, entitled MULTI-COMPONENT ROTORFOR AN ELECTRIC MOTOR OF AN APPLIANCE, now U.S. Pat. No. 10,326,323, theentire disclosures of which are hereby incorporated herein by reference.

BACKGROUND

The device is in the field of rotors for electric motors. Specifically,the device relates to a rotor hub fora rotor of an electric motorincluded within a laundry appliance.

SUMMARY

In at least one aspect, a motor for a laundry appliance includes a driveshaft coupled to a drum at a first end. The rotor frame is coupledproximate the second end of the drive shaft, where the rotor frameincludes at least one polymeric material. A central hub includes a coreand a perimetrical ring that extends circumferentially around the core.A plurality of recesses are defined within a planar surface of theperimetrical ring, wherein a portion of the polymeric material isreceived within the plurality of recesses to secure the rotor frame tothe central hub.

In at least another aspect, a rotor for a motor for driving a laundryappliance includes a rotor frame having at least one polymeric material.A central hub includes a core defining a core outer surface and aperimetrical ring concentrically offset from and outside of the coreouter surface. The perimetrical ring includes a ring outer surface andan inner ring surface. The inner ring surface and the core outer surfacedefine an attachment portion, wherein a portion of the at least onepolymeric material is received within the attachment portion to securethe polymeric frame to the central hub.

In at least another aspect, a motor for a laundry appliance includes adrive shaft that is coupled to a drum at a first end. A rotor frame iscoupled proximate the second end of the drive shaft. The rotor frameincludes at least one polymeric material. A central hub includes a coreand a perimetrical ring that is offset from an outside of the core. Anattachment portion is defined between the perimetrical ring and theoutside of the core. A portion of the at least one polymeric material isreceived within the attachment portion to secure the polymeric frame tothe central hub.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a top perspective view of a laundry appliance incorporating amotor that includes an aspect of the dual-ring rotor hub;

FIG. 2 is a cross-sectional view of a direct drive motor for a laundryappliance having a rotor that incorporates an aspect of the dual-ringrotor hub;

FIG. 3 is a top perspective view of a rotor for a motor incorporating anaspect of the dual-ring rotor hub;

FIG. 4 is a cross-sectional view of the rotor of FIG. 3 taken along lineIV-IV;

FIG. 5 is a top perspective view of an aspect of the dual-ring rotorhub;

FIG. 6 is a cross-sectional view of the dual-ring rotor hub of FIG. 5,taken along line VI-VI;

FIG. 7 is an enlarged cross-sectional view of the rotor of FIG. 4 takenat area VII;

FIG. 8 is a top perspective view of another aspect of a dual-ring rotorhub; and

FIG. 9 is a top perspective view of another aspect of a dual-ring rotorhub.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-7, reference numeral 10 generally refers to amotor for an appliance 12, such as a laundry appliance. According to thevarious embodiments, a motor 10 for the laundry appliance 12, such as adirect drive, incudes a drive shaft 14 that is coupled to a drum 16 at afirst end 18. A rotor frame 20 is coupled proximate a second end 22 ofthe drive shaft 14, where the rotor frame 20 includes at least onepolymeric material 24. A central hub, in the form of a dual-ring rotorhub 26, is included within the rotor frame 20, where the centraldual-ring rotor hub 26 has a core 28 and a perimetrical ring 30 thatextends circumferentially around the core 28. A plurality of recesses 32are defined within a planar surface 34 of the perimetrical ring 30,wherein a portion of the polymeric material 24 is received within theplurality of recesses 32 to secure the rotor frame 20 to the centraldual-ring rotor hub 26. It is also contemplated that a plurality ofsecond recesses 36 can be defined within a second planar surface 38 ofthe perimetrical ring 30, wherein a portion of the polymeric material 24is also received within the plurality of second recesses 36 to securethe rotor frame 20 to the central dual-ring rotor hub 26.

Referring again to FIGS. 2-7, it is contemplated that the variousrecesses 32 defined within the planar surface 34 and the second planarsurface 38 can define an attachment portion 50 of the central dual-ringrotor hub 26. It is contemplated that this attachment portion 50 of thecentral dual-ring rotor hub 26 can be set between the inner ring 52 thatdefines the core 28 and the outer perimetrical ring 30 that extendsaround the core 28. It is contemplated that the planar surface 34 andthe second planar surface 38 of the perimetrical ring 30 can be parallelplanes, where the perimetrical ring 30 defines a ring shape having aconsistent thickness which extends in a concentric offset manner aroundthe core 28 of the central dual-ring rotor hub 26. According to variousalternate embodiments, it is contemplated that the planar surface 34 andthe second planar surface 38 can be out of parallel, such that theconfiguration of the planar surface 34 and the second planar surface 38contributes to the strength of the connection between the centraldual-ring rotor hub 26 and the rotor frame 20.

According to the various embodiments, as exemplified in FIGS. 2-7, it iscontemplated that the rotor frame 20 can include an inner polymericportion 60 that is made of at least one polymeric material 24. In suchan embodiment, when the rotor frame 20 is formed, at least a portion ofthe polymeric material 24 is injected, compressed, or otherwise formedinto the recesses 32 and/or the second recesses 36 of the perimetricalring 30 of the central dual-ring rotor hub 26. In this manner, theforming of the polymeric material 24 within the recesses 32 and thesecond recesses 36 laterally and rotationally secures the rotor frame 20to the central dual-ring rotor hub 26. As such, the polymeric material24 of the inner polymeric portion 60 of the rotor frame 20 flows aroundthe perimetrical ring 30 of the central dual-ring rotor hub 26 and intothe recesses 32 and second recesses 36 defined by the attachment portion50 located between the core 28 and the perimetrical ring 30.

Referring again to FIGS. 1-4, according to an exemplified andnon-limiting aspect of the appliance 12, the direct drive motor 10 intowhich the dual-ring rotor hub 26 is positioned includes a rotor 70connected to the drive shaft 14 that extends between the rotor 70 and adrum 16 of the appliance 12. The drum 16 is set within a tub 72 thatreceives wash water for cleaning various articles set within the drum16. The direct drive motor 10 is attached proximate the tub 72, where astator 74 of the direct drive motor 10 is coupled to a portion of thetub 72, thereby substantially fixing the location of the stator 74.Disposed in the tub 72 is a bearing housing 76 including at least onebearing 78 that allows the drive shaft 14 to be rotated within the wall80 of the tub 72. In this manner, as the rotor 70 rotates about thestator 74, the connection of the rotor 70 to the drum 16 via the driveshaft 14 allows for the transfer of torque from the rotor 70 to thedrive shaft 14 and, in turn, to the drum 16. Typically, the rotor 70includes magnets 82 that are in communication with windings 84 of thestator 74 and form a permanent synchronous motor 10. It is contemplatedthat other types of electric motors 10 can be utilized in conjunctionwith the dual-ring rotor hub 26, where the motor 10 includes a rotor 70that rotates relative to a stator 74. It is contemplated that the rotor70 can rotate within the stator 74, outside the stator 74, or caninclude a dual-rotor configuration that rotates inside and outside ofthe stator 74. Such motors 10 in which the dual-ring rotor hub 26 can beused can include, but are not limited to, direct drives, motors 10 thatare coupled to transmissions, belt-drive motors 10, and other similarelectric motors. Additionally, the various aspects of the dual-ringrotor hub 26 can be used in various orientations of motor 10, includingmotors 10 that are positioned along a vertical axis, a horizontal axisand/or an angled axis. Additionally, the various motors 10 using thedual-ring rotor hub 26 and the various embodiments of the rotor 70 canhave inner rotor, outer rotor or dual rotor configurations.

According to the various embodiments, the various aspects of the rotor70 described herein can be utilized in various electric motors 10 foruse in a variety of appliances 12. These appliances 12 can includefront-load washers, top-load washers, dryers, and other similarappliances 12 having a rotational aspect driven by an electric motor 10.

Referring again to FIGS. 2-7, according to the various embodiments, theconnection between the dual-ring rotor hub 26 and the rotor frame 20 isconfigured to be a substantially strong connection to withstand therotational forces exerted on the connection between the rotor frame 20and the dual-ring rotor hub 26 as the rotor 70 is rotated about thestator 74 to drive the drum 16 and various loads disposed therein. Inorder to transfer the loads exerted upon the rotor 70 by the magneticcommunication with the stator 74, the rotor frame 20 can be made ofvarious materials that are configured to allow for the transfer of thesetorque forces from the outer wall 90 of the rotor 70 to the drive shaft14. In this manner, the rotor frame 20 can include a continuouspolymeric material 24 or a plurality of polymeric materials 24, wherethe rotor frame 20 is formed about the plurality of magnets 82 of therotor 70 and also about the perimetrical ring 30 of the dual-ring rotorhub 26. It is also contemplated the rotor frame 20 can be made of avariety of materials, where the rotor frame 20 can include the innerpolymeric portion 60, an outer polymeric portion 92, and at least onemetallic portion, such as a metallic disk 94 that extends between theinner polymeric portion 60 and the outer polymeric portion 92. In suchan embodiment, it is contemplated that the inner and outer polymericportions 60, 92 can be molded around the metallic disk 94 to form therotor frame 20 into a unitary piece having sufficient strength totransfer the rotational and torque-type forces from the outer wall 90 ofthe rotor 70 to the drive shaft 14, via the dual-ring rotor hub 26.

According to the various embodiments, the material of the metallic disk94 can be steel, aluminum, alloys thereof, combinations thereof, andother similar metallic materials. It is contemplated the one or morepolymeric materials 24 can include various formable materials that caninclude, but are not limited to, plastic, resin, polymers,composite-type materials, combinations thereof, and other similarformable materials.

According to the various embodiments, as exemplified in FIGS. 2-4, it iscontemplated that the inner polymeric portion 60 and the outer polymericportion 92 can be made of separate polymeric materials. The stressesexperienced by the inner polymeric portion 60 proximate the dual-ringrotor hub 26 can be higher than those experienced by the outer polymericportion 92 where the rotor 70 is in magnetic communication with thestator 74. As such, a highly-rigid polymeric material may be used toform the outer polymeric portion 92. The use of this highly rigidpolymeric material can serve to mitigate noise generation during use ofthe motor 10 of the appliance 12. Such a rigid polymeric material foruse in the outer polymeric portion 92 can include, but is not limitedto, a bulk molding compound (BMC) and other similar highly rigidpolymers. Alternatively, it is contemplated that a different polymer canbe used to form the inner polymeric portion 60 that engages thedual-ring rotor hub 26. At this location of the rotor 70, cyclic highstresses can occur in the inner polymeric portion 60 with less soundissues being present. As such, the inner polymeric portion 60 can bemade of various plastic materials that can include, but are not limitedto, glass-filled polybutylene terephthalate (PBT), polypropylene, nylon,combinations thereof, and other similar high-performance polymers.

Referring again to the various embodiments exemplified in FIGS. 2-4, theouter polymeric portion 92 can also include a stiffening flange 104 thatextends around the outer perimeter 106 of the outer polymeric portion92. The stiffening flange 104 can increase the rigidity of the rotor 70by stiffening the circular profile of the rotor 70. In this manner, thestiffening flange 104 can serve to counteract various deflections anddeformations occurring in the rotor 70 during use.

Referring again to FIGS. 2-7, the dual-ring rotor hub 26 can be made ofa metallic material, where such metallic materials can include, but arenot limited to, steel, aluminum, aluminum alloy, and other formablemetallic materials. In this manner, the dual-ring rotor hub 26 can beformed of a single integral piece through metal forming. While metallicmaterials are typical for the formation of the central dual-ring rotorhub 26, it is contemplated that various resins and other plastic-typematerials can be used for the central dual-ring rotor hub 26.

Referring again to FIGS. 2-7, the recesses 32 and second recesses 36defined within the attachment portion 50 between the perimetrical ring30 and the core 28 can include various configurations and alignments. Byway of example, and not limitation, it is contemplated that the recesses32 defined within the planar surface 34 of the perimetrical ring 30 canbe configured to be in vertical alignment with the various secondrecesses 36 defied within the second planar surface 38 of theperimetrical ring 30. Alternatively, the recesses 32 and second recesses36 can be defined as being free of vertical alignment or out of verticalalignment with one another. The various alignments of the recesses 32and the second recesses 36 of the attachment portion 50 can bedetermined based upon the design of the appliance 12, the design of therotor 70, and the various structural needs of the connection between therotor frame 20 and the dual-ring rotor hub 26.

Referring again to FIGS. 2-7, it is contemplated that the inner ring 52defined by the core 28 can include a drive shaft receptacle 100. Thedrive shaft receptacle 100 of the central dual-ring rotor hub 26 caninclude a plurality of grooves, or interior teeth 102, that are adaptedto engage a plurality of corresponding shaft grooves (not shown)positioned proximate the second end 22 of the drive shaft 14.Accordingly, the torque-type forces exerted upon the rotor 70 at theelectromagnetic engagement between the rotor 70 and the stator 74 aretransferred through the rotor frame 20 and to the dual-ring rotor hub 26at the engagement between the rotor frame 20 and the attachment portion50 of the dual-ring rotor hub 26. These torque-type forces are thentransferred to the drive shaft 14 through the engagement of thedual-ring rotor hub 26 at the plurality of interior teeth 102 definedwithin the drive shaft receptacle 100 and the plurality of shaft groovesat the second end 22 of the drive shaft 14. It is contemplated that thedrive shaft 14 can be connected to the drive shaft receptacle 100through various other connection methods. These connection methods caninclude, but are not limited to, fasteners, adhesives, welding,interference mechanisms, threads, combinations thereof and otherconnection methods.

Referring again to FIGS. 2-7, the rotor 70 for the direct drive motor 10can include the rotor frame 20 having one or more polymeric materials24. Again, the polymeric material 24 can extend continuously through therotor frame 20 or can be used in conjunction with various metallic orother dissimilar materials to form a unitary rotor frame 20. Centrallydisposed within the rotor frame 20 is the central dual-ring rotor hub 26that includes the core 28 defining a core outer surface 110 and aperimetrical ring 30 concentrically offset from and outside the coreouter surface 110. The perimetrical ring 30 includes an outer ringsurface 112 and an inner ring surface 114. It is contemplated that thespace between the inner ring surface 114 and the core outer surface 110define an attachment portion 50. At least a part of the at least onepolymeric material 24 can be received within the attachment portion 50to secure the rotor frame 20 to the central dual-ring rotor hub 26.

Referring again to FIGS. 4-7, it is contemplated the attachment portion50 of the dual-ring rotor hub 26 can include a circumferential wall 120that extends between the core outer surface 110 and the inner ringsurface 114. The circumferential wall 120 substantially divides theattachment portion 50 into opposing first and second channels 122, 124.The circumferential wall 120 disposed through the attachment portion 50can be oriented to be substantially parallel with a base 128 of therotor frame 20 and substantially perpendicular to an axis of rotation130 of the drive shaft 14. In this manner, the first and second channels122, 124 of the attachment portion 50, being separated by thecircumferential wall 120, are each configured to receive at least aportion of the polymeric material 24 of the rotor frame 20. In order tofurther the engagement between the polymeric material 24 of the rotorframe 20 and the attachment portion 50 of the dual-ring rotor hub 26,the circumferential wall 120 can include various perforations 132 thatextend at least partially into the circumferential wall 120.

According to various embodiments, it is also contemplated that theseperforations 132 can extend through the circumferential wall 120, suchthat the first and second channels 122, 124 of the attachment portion 50are at least partially in communication with one another through thecircumferential wall 120. In such an embodiment, as the polymericmaterial 24 is formed into the first and second channels 122, 124, thepolymeric material 24 can extend from the first channel 122 and into atleast a portion of the second channel 124, and vice versa. It is alsocontemplated that the circumferential wall 120 can be free of, orsubstantially free of, perforations 132, such that the first and secondchannels 122, 124 of the attachment portion 50 are fully divided by thecircumferential wall 120 extending between the core outer surface 110and the inner ring surface 114.

Referring again to FIGS. 3-7, in addition to the circumferential wall120, it is contemplated that the attachment portion 50 can include aplurality of radial walls 140 that extend from at least one of the coreouter surface 110 and the inner ring surface 114. In this manner, theplurality of radial walls 140 are configured to divide the first channel122 into the plurality of recesses 32. It is also contemplated that theplurality of radial walls 140 can divide the second channel 124 into theplurality of second recesses 36. According to the various embodiments,the plurality of radial walls 140 are configured to extend radiallyoutward from the axis of rotation 130 of the drive shaft 14. It is alsocontemplated that the radial walls 140 can include some othergeometrical orientation, where such orientations can include, but arenot limited to, grid-type configurations, irregular configurations,concentric configurations, combinations thereof, and other similargeometric configurations.

According to the various embodiments, the plurality of radial walls 140can extend fully between the inner ring surface 114 and the core outersurface 110. In such an embodiment, the recesses 32 and second recesses36 disposed within the attachment portion 50 are fully separated andeach of the recesses 32 and each of the second recesses 36 individuallyreceives portions of the polymeric material 24 when the rotor frame 20is being formed. It is also contemplated that the plurality of radialwalls 140 can extend only partially between the inner ring surface 114and the core outer surface 110 (exemplified in FIG. 8). In such anembodiment, the various recesses 32 and second recesses 36 can be atleast partially in communication with one another, respectively.

Referring again to FIGS. 3-7, it is contemplated that the attachmentportion 50 defined between the perimetrical ring 30 and the core 28 canbe substantially free of the circumferential wall 120 described above.In such an embodiment, the attachment portion 50 can include theplurality of radial walls 140 that extend between the core outer surface110 and the inner ring surface 114. In such an embodiment, the pluralityof radial walls 140 serve to divide the attachment portion 50 into aplurality of attachment cavities that are defined by the recesses 32 andsecond recesses 36 when the circumferential wall 120 is omitted. Theplurality of attachment cavities each receive a portion of the polymericmaterial 24 to define the engagement between the rotor frame 20 and thedual-ring rotor hub 26.

According to the various embodiments, it is contemplated that theplurality of radial walls 140 can include a plurality of first radialwalls 150 that are disposed in the first channel 122 and a plurality ofsecond radial walls 152 that are disposed in the second channel 124. Insuch an embodiment, it is contemplated that the plurality of firstradial walls 150 can be free of alignment with the plurality of secondradial walls 152. In embodiments having the circumferential wall 120,this configuration results in the recesses 32 being free of alignmentwith the second recesses 36. In the various embodiments being free ofthe circumferential wall 120, the lack of vertical alignment between thefirst radial walls 150 and the second radial walls 152 can define aseries of alternating attachment cavities defined between the first andsecond radial walls 150, 152 positioned within the attachment portion 50between the perimetrical ring 30 and the core 28.

The attachment portion 50 defined between the perimetrical ring 30 andthe core 28 can include various configurations of the radial walls 140,circumferential wall 120, recesses 32, and second recesses 36 that areconfigured to maintain the structural integrity of the engagementbetween the rotor frame 20 and the dual-ring rotor hub 26. The exactconfigurations of the various features defined between the perimetricalring 30 and the core 28 can vary in order to secure the polymericmaterial 24 within the attachment portion 50 of the dual-ring rotor hub26.

Referring again to FIGS. 2-7, the direct drive motor 10 can include thedrive shaft 14 that is coupled to the drum 16 at the first end 18. Therotor frame 20 is coupled proximate the second end 22 of the drive shaft14, where the rotor frame 20 includes at least one polymeric material 24that is configured to engage the central dual-ring rotor hub 26. Thecentral dual-ring rotor hub 26 includes the core 28 and the perimetricalring 30 that is offset from and outside of the core 28. The attachmentportion 50 is defined between the core 28 and the perimetrical ring 30.In this manner, a portion of at least one polymeric material 24 isreceived within the attachment portion 50 to secure the rotor frame 20to the central dual-ring rotor hub 26.

According to the various embodiments, the various radial walls 140and/or circumferential walls 120 can be included within the attachmentportion 50 to define the recesses 32, second recesses 36, attachmentcavities, and other securing features to allow the polymeric material 24to be formed within the attachment portion 50, such that the primaryattachment between the rotor frame 20 and the dual-ring rotor hub 26occurs within the attachment portion 50. Accordingly, the outer ringsurface 112 of the perimetrical ring 30 can be substantially smooth andfree of the various protrusions, teeth, or other outwardly extendingsecuring features. The lack of these features can provide for an easiersystem of forming the various structures of the dual-ring rotor hub 26.Similarly, the core outer surface 110 of the core 28 above and below theperimetrical ring 30 can also be made to be free of protrusions, teeth,and other outwardly extending features. Accordingly, the engagementbetween the rotor frame 20 and the dual-ring rotor hub 26 is primarilydefined between the perimetrical ring 30 and the core 28. In thismanner, the various physical features disposed within the attachmentportion 50 of the dual-ring rotor hub 26 allow for a secure engagementbetween the polymeric material 24 and the various physical features ofthe attachment portion 50 of the dual-ring rotor hub 26.

According to the various embodiments, it is typical that the outer ringsurface 112 of the perimetrical ring 30 and the core outer surface 110of the core 28 above and below the perimetrical ring 30 will be asubstantially smooth and cylindrical surface that is free orsubstantially free of protrusions, teeth, and other outwardly extendingfeatures. It is contemplated, though not typical, that the outer surfaceof the perimetrical ring 30 and the outward-facing surface of the core28, above and below the perimetrical ring 30, can include variousprotrusions and other outwardly extending features to further define theengagement between the rotor frame 20 and the dual-ring rotor hub 26.

Referring now to the various embodiments of the device as exemplified inFIG. 8, it is contemplated that the attachment portion 50 of a dual-ringrotor hub 26 can include various undulating surfaces 160 that define asubstantially continuous recess 32 that extends circumferentiallybetween the core 28 and the perimetrical ring 30. These undulatingsurfaces 160 can extend from the outer core surface 110, the inner ringsurface 114, or a combination of both. As discussed above, theundulating surfaces 160 defined between the perimetrical ring 30 and thecore 28 can include various radial walls 140 that extend partiallybetween the perimetrical ring 30 and the core 28 to define theundulating surface 160 and resulting recess 32 defined within theattachment portion 50 of the dual-ring rotor hub 26.

Referring now to various aspects of the device as is exemplified in FIG.9, it is contemplated that the perimetrical ring 30 can be defined by adiscontinuous member that includes vertically undulating portions 170.In such an embodiment, the recesses 32 defined within a first surface ofthe perimetrical ring 30 can be further defined by the verticallyundulating portions 170 of the perimetrical ring 30. Accordingly, thevertically undulating portions 170 of the perimetrical ring 30corresponds to a plurality of vertically undulating recesses 32 andsecond recesses 36 defined within the first and second surfaces of theperimetrical ring 30. In such an embodiment, it is contemplated that thevertically undulating portions 170 and the perimetrical ring 30 canfurther define the attachment portion 50 of the dual-ring rotor hub 26.In the vertically undulating configurations of the perimetrical ring 30,these vertically undulating portions 170 can be defined by curvilinearundulations, rectilinear undulations, offset portions of theperimetrical ring 30, and other generally sinusoidal geometricalundulations that occur circumferentially about the core 28 of thedual-ring rotor hub 26.

According to the various embodiments, the primary engagement between therotor frame 20 and the dual-ring rotor hub 26 occurs within theattachment portion 50 defined between the perimetrical ring 30 and thecore outer surface 110. In this manner, the polymeric material 24 of therotor frame 20 is configured to conform around the perimetrical ring 30and into the attachment portion 50. In this manner, resistance to thevarious rotational and axial forces exerted between the rotor 70, thestator 74, and the drive shaft 14 are received within the attachmentportion 50 and the perimetrical ring 30 and transferred through theattachment portion 50 to the core 28 and into the drive shaft receptacle100 and to the drive shaft 14 for transferring the torque from the driveshaft 14 to the drum 16. By locating the attachment portion 50 outwardfrom the core 28, the engagement between the rotor frame 20 and thedual-ring rotor hub 26 is positioned further outward from the axis ofrotation 130 of the drive shaft 14 than other conventional rotor hubs.The use of the perimetrical ring 30 to extend the dual-ring rotor hub 26in an outward direction within the rotor frame 20 serves to provide amore efficient transfer of torque from the rotor frame 20, through thedual-ring rotor hub 26, and into the drive shaft 14 for transferringtorque from the drive shaft 14 to the drum 16 of the appliance 12.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A metallic coupler for a polymeric rotor, themetallic coupler comprising: a core that is configured to receive adrive shaft; an outer perimetrical ring that extends around the core anddefines a cylindrical outer surface; and a plurality of recessespositioned within an inner surface of the outer perimetrical ring,wherein the plurality of recesses are configured to receive at least onepolymeric material, and wherein the plurality of recesses are definedbetween an outer surface of the core and the inner surface of the outerperimetrical ring, wherein the plurality of recesses are furtherconfigured to rotationally and axially secure a rotor frame that isformed of the at least one polymeric material.
 2. The metallic couplerof claim 1, wherein the plurality of recesses are defined by a pluralityof radial walls that extend between the outer surface of the core andthe inner surface of the outer perimetrical ring, wherein the pluralityof recesses are configured to each receive at least a portion of the atleast one polymeric material.
 3. The metallic coupler of claim 2,wherein the plurality of recesses are defined within a planar surface ofthe outer perimetrical ring and a plurality of second recesses aredefined within a second planar surface of the outer perimetrical ring,and wherein the plurality of second recesses are also configured toreceive a portion of the at least one polymeric material of the rotorframe.
 4. The metallic coupler of claim 3, wherein the planar surfaceand the second planar surface are parallel.
 5. The metallic coupler ofclaim 1, wherein the core and the outer perimetrical ring are formed ofaluminum.
 6. The metallic coupler of claim 3, wherein the plurality ofrecesses are in vertical alignment with the plurality of secondrecesses.
 7. The metallic coupler of claim 3, wherein the plurality ofrecesses are vertically offset with respect to the plurality of secondrecesses.
 8. The metallic coupler of claim 3, wherein a circumferentialwall extends between the outer surface of the core and the inner surfaceof the outer perimetrical ring, and wherein the circumferential walldefines the planar surface and the second planar surface.
 9. Themetallic coupler of claim 8, wherein the circumferential wall separatesthe plurality of recesses from the plurality of second recesses.
 10. Ametallic coupler for a polymeric rotor, the metallic coupler comprising:a core defining a core outer surface; an attachment portion that isdefined by the core outer surface; an outer perimetrical ring positionedoutside of the core and having an inner surface that further defines theattachment portion, wherein the attachment portion is defined betweenthe core outer surface and the inner surface of the outer perimetricalring, and wherein the attachment portion is configured to receive apolymeric material to secure a rotor frame that is made from thepolymeric material.
 11. The metallic coupler of claim 10, wherein theattachment portion includes a plurality of radial walls that extendbetween the core outer surface and the inner surface of the outerperimetrical ring.
 12. The metallic coupler of claim 11, wherein theplurality of radial walls divides the attachment portion into aplurality of attachment cavities, wherein the plurality of attachmentcavities are configured to each receive at least a portion of thepolymeric material.
 13. The metallic coupler of claim 10, wherein theattachment portion includes a circumferential wall extending between thecore outer surface and the inner surface, wherein the circumferentialwall divides the attachment portion into opposing first and secondchannels.
 14. The metallic coupler of claim 13, wherein thecircumferential wall is free of perforations.
 15. The metallic couplerof claim 13, wherein the attachment portion includes a plurality ofradial walls that extend from at least one of the core outer surface andthe inner surface, wherein the plurality of radial walls divides thefirst channel into a plurality of recesses, and wherein the plurality ofradial walls divides the second channel into a plurality of secondrecesses.
 16. The metallic coupler of claim 15, wherein the plurality ofradial walls includes a plurality of first radial walls disposed withinthe first channel and a plurality of second radial walls disposed withinthe second channel, and wherein the plurality of first radial walls arefree of alignment with the plurality of second radial walls.
 17. Ametallic coupler for a polymeric rotor, the metallic coupler comprising:a core that is configured to receive a drive shaft; an attachmentportion extending concentrically around an outer surface of the core; anouter perimetrical ring positioned concentrically outside of the core,wherein an inner surface of the outer perimetrical ring further definesthe attachment portion, wherein the attachment portion is configured toreceive a portion of a polymeric material to secure a rotor frame thatis made of the polymeric material.
 18. The metallic coupler of claim 17,wherein the attachment portion includes a circumferential wall thatextends between the outer surface of the core and the inner surface ofthe outer perimetrical ring, wherein the circumferential wall dividesthe attachment portion into opposing first and second channels.
 19. Themetallic coupler of claim 17, wherein the attachment portion includes aplurality of radial walls that extend from the outer surface of the coreto the inner surface of the outer perimetrical ring.
 20. The metalliccoupler of claim 18, wherein the circumferential wall is free ofperforations.